EP1356479B1 - Spulenbauteil und verfahren zu seiner herstellung - Google Patents

Spulenbauteil und verfahren zu seiner herstellung Download PDF

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Publication number
EP1356479B1
EP1356479B1 EP02700796A EP02700796A EP1356479B1 EP 1356479 B1 EP1356479 B1 EP 1356479B1 EP 02700796 A EP02700796 A EP 02700796A EP 02700796 A EP02700796 A EP 02700796A EP 1356479 B1 EP1356479 B1 EP 1356479B1
Authority
EP
European Patent Office
Prior art keywords
coil
compressed powder
middle portion
component
magnetic core
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP02700796A
Other languages
English (en)
French (fr)
Other versions
EP1356479A2 (de
Inventor
Toshiyuki Nakata
Tsunetsugu Imanishi
Hiroyuki Hamamoto
Hidetoshi Hiwatashi
Tomokazu Kitagawa
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Panasonic Holdings Corp
Original Assignee
Matsushita Electric Industrial Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from JP2001051803A external-priority patent/JP3612028B2/ja
Priority claimed from JP2002012515A external-priority patent/JP3654251B2/ja
Priority claimed from JP2002015051A external-priority patent/JP3654254B2/ja
Application filed by Matsushita Electric Industrial Co Ltd filed Critical Matsushita Electric Industrial Co Ltd
Publication of EP1356479A2 publication Critical patent/EP1356479A2/de
Application granted granted Critical
Publication of EP1356479B1 publication Critical patent/EP1356479B1/de
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H01F27/255—Magnetic cores made from particles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00—Fixed inductances of the signal type 
    • H01F17/04—Fixed inductances of the signal type  with magnetic core
    • H01F17/043—Fixed inductances of the signal type  with magnetic core with two, usually identical or nearly identical parts enclosing completely the coil (pot cores)
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/02—Casings
    • H01F27/022—Encapsulation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H01F27/26—Fastening parts of the core together; Fastening or mounting the core on casing or support
    • H01F27/263—Fastening parts of the core together
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00—Cores, Yokes, or armatures
    • H01F3/10—Composite arrangements of magnetic circuits
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
    • H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00—Fixed inductances of the signal type 
    • H01F17/04—Fixed inductances of the signal type  with magnetic core
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00—Fixed inductances of the signal type 
    • H01F17/04—Fixed inductances of the signal type  with magnetic core
    • H01F17/045—Fixed inductances of the signal type  with magnetic core with core of cylindric geometry and coil wound along its longitudinal axis, i.e. rod or drum core
    • H01F2017/046—Fixed inductances of the signal type  with magnetic core with core of cylindric geometry and coil wound along its longitudinal axis, i.e. rod or drum core helical coil made of flat wire, e.g. with smaller extension of wire cross section in the direction of the longitudinal axis
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/02—Casings
    • H01F27/027—Casings specially adapted for combination of signal type inductors or transformers with electronic circuits, e.g. mounting on printed circuit boards
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2847—Sheets; Strips
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2847—Sheets; Strips
    • H01F27/2852—Construction of conductive connections, of leads
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/29—Terminals; Tapping arrangements for signal inductances
    • H01F27/292—Surface mounted devices
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/005—Impregnating or encapsulating
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/4902—Electromagnet, transformer or inductor

Definitions

  • the present invention relates to a coil component used in various electronic apparatuses, and a method of manufacturing the same.
  • Fig. 9 is a perspective view of a conventional coil component.
  • Fig. 10 is a sectional view of the coil component.
  • Fig. 11 is a sectional view of the coil component showing a part of the manufacturing process of the coil component.
  • the conventional coil component comprises a coil 52 having a through-hole, a packaging 53 made up of magnetic material with the coil 52 disposed therein, and a terminal 54 connected to the coil 52.
  • the packaging 53 is formed by molding magnetic powder 55 under pressure so as to cover the coil 52.
  • the packaging 53 is formed under a constant molding pressure over the entire part thereof, and also the packaging 53 is nearly uniform in density over the entire part thereof.
  • the height of the packaging 53 can be lowered by compressing the packaging 53, the top and bottom portions of the packaging 53 are also reduced in thickness. Accordingly, there has been a problem that magnetic saturation is liable to occur, worsening the reliability, when the magnetic flux passing in the through-hole of the coil 52 passes through the top and bottom portions of the packaging 53. ,
  • the present invention provides a coil component improved in reliability, in which magnetic saturation hardly occurs even when the top and bottom portions of the coil component are reduced in thickness for the purpose of lowering the height of the coil component.
  • a packaging of the coil component of the present invention is a compressed powder magnetic core containing magnetic powder, comprising a top portion disposed at an upper part of the coil, a bottom portion disposed at a lower part of the coil, and a middle portion corresponding to the height of the coil. Also, the outer layer thickness (distance between the coil and the packaging surface) of the middle portion of the packaging including the coil is less than a diameter of the through-hole of the coil, and at the same time, a density the top portion and the bottom portion are higher than that of the middle portion.
  • a density of the inside of the through-hole of the coil which corresponds to the middle portion of the packaging, is lower than densities of the top and bottom portions of the packaging. Accordingly, even when the magnetic flux passing through the through-hole passes through the top and bottom portions whose thickness is less than the diameter of the through-hole, magnetic saturation does not occur at the top and bottom portions, enabling the lowering of the height of the coil component. This is because the magnetic permeability can be increased in the top and bottom portions where the packaging density is higher than the middle portion.
  • a coil component in an embodiment of the present invention is 2 to 5 mm high and 10 mm square in shape, comprising a coil 2 having a through-hole 1, a packaging 3 including the coil 2, and terminals 4 connected to the coil 2.
  • the packaging 3 is a compressed powder magnetic core (dust core) containing magnetic powder.
  • the materials for the packaging 3 comprise thermosetting binder resin comprising silicone resin of tough resin component and elastic resin component and magnetic powder. The materials are mixed without heating so that the thermosetting resin does not cure and is molded under a pressure ranging from 0.5 to 2.0 t/cm 2 , thereby forming compressed powder 5. Further, the compressed powder 5 is subjected to re-molding under a pressure ranging from 3.0 to 5.0 t/cm 2 so as to encapsulate the coil 2 while being heated at 100°C to 180°C so that the thermosetting resin completely cures, thereby molding packaging 3.
  • the compressed powder magnetic core employs heat-treated soft magnetic alloy powder as magnetic powder.
  • the magnetic alloy powder ranges from 1 ⁇ m to 100 ⁇ m in average particle diameter, and it includes component A, chrome (Cr), oxygen (O), manganese (Mn), carbon (C) and iron (Fe).
  • Component A includes at least one selected from the group consisting of silicon (Si), aluminum (Al), titanium (Ti) and magnesium (Mg).
  • each component is as follows: 1 wt % ⁇ component A ⁇ 7 wt %, 2 wt % ⁇ Cr ⁇ 8 wt %, 0.05 wt % ⁇ O ⁇ 0.6 wt %, 0.01 wt % ⁇ Mn ⁇ 0.2 wt %, 0.005 wt % ⁇ C ⁇ 0.2 wt %, and the rest is iron (Fe).
  • Ni nickel
  • Ni nickel
  • Two pieces of compressed powder 5 are used for molding the packaging 3 as shown in Fig.3(b).
  • the compressed powder 5 is provided with a strong portion where the shape of compressed powder 5 is not collapsed by the pressure applied during re-molding operation and a weak portion where the shape of compressed powder 5 is collapsed due to the pressure applied during re-molding operation.
  • the compressed powder 5 is a pot shape with an E-shaped cross section with back portion 6, a central portion 7 and an outside portion 8, and the back portion 6 serves as a strong portion, while the central portion 7 and the outside portion 8 respectively serve as a weak portion.
  • the weak portion and the strong portion are formed by controlling the density of the compressed powder. That is, the density of compressed powder is lower at the weak portion, and higher at the strong portion.
  • the strength of the weak portion is such that the shape is collapsed when a pressure of a few kg/cm 2 is applied.
  • the expression that the shape of compressed powder 5 is "collapsed” means that the shape is collapsed to a size of particle size of the magnetic powder.
  • a state of being broken into blocks (lumps) is not included in the range of being weak since the shape is not broken into the particle size of the magnetic powder.
  • the compressed powder in molding the packaging 3, is re-molded under pressure so that the top and bottom of coil 2 are held by the strong portions of two pieces of compressed powder 5 and that the outer periphery of coil 2 and the inner part of through-hole 1 are covered with the weak portion collapsed. Also, the compressed powder is heated during the re-molding under pressure so that the thermosetting resin completely cures.
  • the packaging 3 is molded so that an outer layer thickness (W1) shown in Fig.1 of the middle portion including the coil 2 is less than a diameter of the through-hole 1 of the coil 2. Also, as for the top portion 11 at the upper part of coil 2, the bottom portion 12 at the lower part of coil 2 and the middle portion 13 at the height part of coil 2, the top portion 11 and the bottom portion 12 are higher in density than the middle portion 13.
  • the middle portion 13 is formed so that a density of the outside middle portion 14 is higher than a density of the inside middle portion 15.
  • the densities of the top portion 11 and bottom portion 12 are in a range from 5.0 to 6.0 g/cm 3 and that of the inside middle portion 13 is 85% to 98% of the densities of the top portion 11 and bottom portion 12.
  • the manufacturing method of the prevent invention comprises an packaging molding process for encapsulating coil 2 in packaging 3 made up of magnetic material, and a terminal forming process for forming terminals 4 connected to the coil 2.
  • the packaging molding process comprises a step of molding two pieces of compressed powder 5 where a thermosetting resin binder, which include silicone resin having tough resin component and elastic resin component, and magnetic powder are mixed without heating so that the thermosetting resin does not cure, and are molded under pressure.
  • a thermosetting resin binder which include silicone resin having tough resin component and elastic resin component, and magnetic powder are mixed without heating so that the thermosetting resin does not cure, and are molded under pressure.
  • Compressed powder 5 has a pot shape with an E-shaped cross section with back portion 6, a central portion 7 and an outside portion 8, and the back portion 6 is a strong portion being able to keep the shape of compressed powder 5 during re-molding under pressure, while the central portion and the outside portion respectively serve as a weak portion being unable to keep the shape of compressed powder 5 during re-molding under pressure.
  • the coil 2 is placed in the mold so that the top and bottom thereof are held by the strong portions of two pieces of compressed powder 5, then the two pieces of compressed powder 5 are re-molded under heat and pressure for molding the packaging 3.
  • the outer periphery of coil 2 and the inside of through-hole 1 are covered with the weak portion.
  • the back portion 6 (strong portion) of compressed powder 5 opposing to the inner part of through-hole 1 of coil 2 is buried into the through-hole 1 of coil 2 in a block. Also, while the back portion 6 (strong portion) of compressed powder 5 opposing to terminal 4 is buried toward the terminal 4 in a block, the central portion 7 (weak portion) and outside portion 8 (weak portion) of compressed powder 5 are collapsed, thereby covering the other outer periphery of coil 2 and the inner part of through-hole 1.
  • top portion 11 at the upper part of coil 2 and bottom portion 12 at the lower part of coil 2 are formed higher in density than the middle portion 13 corresponding to the height part of coil 2.
  • middle portion 13 there are provided inside middle portion 15 corresponding to the through-hole 1 of coil 2 and outside middle portion 14 corresponding to the outer periphery of coil 2, and the outside middle portion 14 is formed higher in density than the inside middle portion 15.
  • the packaging 3 is molded so that the densities of the top portion 11 and bottom portion 12 is in a range from 5.0 to 6.0 g/cm 3 , while that of the inner middle portion 13 is 85% to 98% of the densities.
  • the top portion 11 and bottom portion 12 of the packaging 3 are higher in density than the inner part of middle portion 13, which corresponds to the inside of through-hole 1. Accordingly, even when the magnetic flux passing through the through-hole 1 passes through the top portion 11 and the bottom portion 12 whose thickness (W2, W3) is less than the diameter of through-hole 1, the top portion 11 and the bottom portion 12 can be possible to obtain higher magnetic permeability as the top portion 11 and the bottom portion 12 are higher in density than the middle portion 13. As a result, the height of the coil component can be lowered without allowing the occurrence of magnetic saturation at the top portion 11 and the bottom portion 12.
  • the middle portion 13 includes inside middle portion 15 corresponding to through-hole 1 and outside middle portion 14 corresponding to the outside portion of coil 2. Since the outside middle portion 14 is higher in density than the inside middle portion 15, outside middle portion 14 is possible to obtain higher magnetic permeability. Accordingly, it is possible to reduce the size of the coil component in the lateral direction thereof and to save the space for mounting of the coil component without allowing the occurrence of magnetic saturation at the outside middle portion 14.
  • the packaging 3 is molded so that the densities of the top portion 11 and bottom portion 12 are in a range from 5.0 to 6.0 g/cm 3 and that of the inner middle portion 13 is 85% to 98% of the densities, and therefore, excessive stresses will not be applied to the coil 2.
  • the packaging 3 is a compressed powder magnetic core, and has a specific composition. That is, the ratio of Fe component is high and it is advantageous for DC-Bias characteristics. Moreover, containing Cr component suppresses the generation of rust due to Fe component. Further, since the content of Cr is not more than 8 wt %, it is possible to suppress a loss in a frequency range of higher than 100 kHz. In this way, the present invention is able to realize composite magnetic material having excellent corrosion resistance without losing the magnetic characteristic.
  • an ordinary powder molding is generally uses powder for the molding, but in the present invention where solid compressed powder 5 is used, the quantity of compressed powder 5 between the punch 9 and the coil 2 hardly varies during re-molding under pressure, and the covering thickness of packaging 3 is easier to make uniform over the entire periphery of coil 2. Accordingly, it is possible to suppress the dispersions in characteristics such as inductance, saturation characteristic and magnetic losses during DC-biasing of the inductance. Further, since the coil 2 can be held by compressed powder 5, the coil 2 is precisely positioned, and defective molding of packaging 3 may be prevented. Regarding the compressed powder 5, magnetic powder and binder including thermosetting resin are mixed and pressed to form compressed powder 5. And, the thermosetting resin includes silicone resin having tough resin component and elastic resin component, therefore it is possible to mold the, packaging well balanced in strength and brittleness, and to minimize the defect of packaging 3.
  • coil 2 is covered when compressed powder 5 is re-molded under pressure, the coil 2 can be precisely covered. Also, as gaps between compressed powder 5 and coil 2 can be completely filled, it is possible to improve the magnetic efficiency by reducing the magnetic gaps.
  • the strong portion of compressed powder 5 reliably holds one side of coil 2, the position of coil 2 is hardly misregistrated during re-molding under pressure, and another side of coil 2 can be easily covered with the weak portion of compressed powder 5 as the weak portion collapses. Accordingly, it is possible to make the covering of packaging 3 uniform in thickness over the entire periphery of coil 2 and to suppress the dispersions in characteristics of the coil component.
  • the compressed powder 5 is a pot shape with an E-shaped cross section with back portion 6, a central portion 7 and an outside portion 8, and the back portion 6 is a strong portion, while the central portion 7 and the outside portion 8 respectively serve as a weak portion.
  • positional misregistration hardly occur due to the strong portion of compressed powder 5, and it is easier to cover the other side of coil 2, and the dispersions in characteristics of the coil component can be reduced.
  • the covering of packaging 3 is easier to become uniform in thickness over the entire periphery of coil 2, and it is possible to reduce the dispersions in characteristics and also to obtain higher magnetic permeability in top portion 11 and bottom portion 12 as the top portion 11 and bottom portion 12 of packaging 3 are higher in density than the middle portion 13. Also, the height can be lowered without allowing the occurrence of magnetic saturation at the top portion 11 and the bottom portion 12.
  • the compressed powder 5 has E-shaped cross section, but it is also possible to make the central portion 7 longer or shorter than the outside portion 8 provided that the shape is within the scope of the present invention.
  • a T-shaped cross section with only the central portion 7 formed at the back portion 6 and a C-shaped cross section with only the outside portion 8 formed at the portion can be considered equivalent to the E-shaped cross section of the present embodiment.
  • one side of the coil 2 may be held by a strong portion of one compressed powder 5, while another side of the coil 2 is supported by a weak portion of another compressed powder 5. In that case, it is also allowable to make the strong portion of E-shaped compressed powder 5 higher in density than the weak portion.
  • the coil 2 it is allowable to wind a flat wire as well as a round wire into an edgewise coil. In this case, it is possible to enhance the space factor of the coil and to make it compatible with high current. Especially, when a flat wire is tightly wound so that packaging 3 will not be molded between the adjacent flat wires, it is possible to suppress the generation of magnetic flux that circulates around the flat wire and to reduce the losses since the packaging 3 is not molded between the flat wires.
  • one of the compressed powder 5 can be re-molded under pressure so that one side of the coil 2 is held by the back portion 6 of the strong portion, and another compressed powder 5 is placed so that the central portion 7 is inserted into the through-hole 1 of coil 2.
  • re-molding can be performed using two compressed powders 5 having small peaks and valleys 10 at tip end portions of central portion 7 or the outside portion 8 and opposed to each other. Further, it is also possible to perform re-molding, providing one or more dividing grooves at the back portion 6 of compressed powder 5.
  • one side of the coil 2 is supported by the strong portion of compressed powder 5, but it is preferable to let one side of the coil 2 be supported by the strong portion of the compressed powder even after re-molding under pressure.
  • the present invention as described above, even when the height of a coil component is lowered as a whole by forming the top portion of the packaging, corresponding to the upper part of the coil, and the bottom portion of the packaging, corresponding to the lower part of the coil, less in thickness until the outer layer thickness of the middle portion including the coil becomes less than the diameter of the through-hole of the coil, it is possible to suppress the occurrence of magnetic saturation at the top and bottom portions since the top portion and the bottom portion are higher in density than the middle portion.
  • the density of the inside of the through-hole of the coil which corresponds to the middle portion of the packaging, is lower than the density of the top portion and bottom portion of the packaging. Accordingly, the magnetic permeability can be increased at the top portion and bottom portion as the top portion and bottom portion are higher in density than the middle portion.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Coils Or Transformers For Communication (AREA)

Claims (22)

  1. Spulenbauteil, umfassend:
    eine Spule (2), die eine Durchgangsöffnung (1) hat;
    einen Magnetkern (3), der die genannte Spule enthält; und
    einen Anschluss (4), der mit der genannten Spule verbunden ist, worin
    der genannte Magnetkern (3) einen oberen Abschnitt (11) umfasst, der an einem oberen Teil der genannten Spule angeordnet ist, einen unteren Abschnitt (12), der an einem unteren Teil der genannten Spule angeordnet ist, und einen mittleren Abschnitt (13), der auf der Höhe der genannten Spule angeordnet ist, wobei eine äußere Schichtdicke (W1) des genannten mittleren Abschnitts kleiner ist als ein Durchmesser der genannten Durchgangsöffnung, während die Dichte des genannten oberen Abschnitts (11) und des genannten unteren Abschnitts (12) höher ist als die des genannten mittleren Abschnitts (13).
  2. Spulenbauteil nach Anspruch 1, worin der genannte mittlere Abschnitt einen inneren mittleren Abschnitt umfasst, welcher in der Durchgangsöffnung positioniert ist, und einen äußeren mittleren Abschnitt umfasst, der einen Außenteil der genannten Spule umgibt, wobei die Dichte des genannten äußeren mittleren Abschnitts höher ist als die des genannten inneren mittleren Abschnitts.
  3. Spulenbauteil nach Anspruch 1, worin der genannte Magnetkern so ausgebildet ist, dass Dichten des genannten oberen Abschnitts und des genannten unteren Abschnitts in einem Bereich von 5,0 bis 6,0 g/cm3 sind, und eine Dichte des genannten inneren mittleren Abschnitts 85% bis 98% der Dichten des genannten oberen Abschnitts und des genannten unteren Abschnitts ist.
  4. Spulenbauteil nach Anspruch 1, worin die genannte Spule eine Hochkant-Spule ist, die ausgebildet wird, indem ein Flachdraht in einer solchen Weise gewickelt wird, dass angrenzende Flachdrähte in engem Kontakt miteinander sind.
  5. Spulenbauteil nach Anspruch 1, worin der genannte Magnetkern ein Bindemittel umfasst, das härtbares Kunstharz und magnetisches Pulver umfasst.
  6. Spulenbauteil nach Anspruch 5, worin das genannte härtbare Kunstharz ein Silikon-Kunstharz ist, das einen festen Kunstharzbestandteil und einen elastischen Kunstharzbestandteil umfasst.
  7. Spulenbauteil nach Anspruch 5, worin ein komprimiertes Pulver, das als Material für die Herstellung des genannten Magnetkerns verwendet wird, einen schwachen Anteil umfasst, der nicht in der Lage ist, eine Form des genannten komprimierten Pulvers zu bewahren, und einen starken Anteil umfasst, der in der Lage ist, die Form des genannten komprimierten Pulvers zu bewahren, wenn das genannte komprimierte Pulver umgeformt wird.
  8. Spulenbauteil nach Anspruch 7, worin ein Querschnitt des genannten komprimierten Pulvers eine E-Form mit einem Rückabschnitt, einem Zentralabschnitt und einem Außenabschnitt hat.
  9. Spulenbauteil nach Anspruch 8, worin der Rückabschnitt des genannten komprimierten Pulvers der starke Anteil ist, während der Zentralabschnitt und der Außenabschnitt als der schwache Anteil dienen.
  10. Spulenbauteil nach Anspruch 7, worin ein Spitzende des Zentralabschnitts oder des Außenabschnitts des genannten komprimierten Pulvers kleine Spitzen und Senken hat.
  11. Spulenbauteil nach Anspruch 7, worin mindestens eine teilende Nut am Rückabschnitt des genannten komprimierten Pulvers vorgesehen ist.
  12. Verfahren zur Herstellung eines Spulenbauteils, das die Schritte umfasst:
    Verkapseln einer Spule, welche eine Durchgangsöffnung hat, mit einem Magnetkern, der magnetisches Pulver umfasst; und
    Ausbilden eines Anschlusses, der mit der genannten Spule verbunden ist, worin das genannte Verkapseln so durchgeführt wird, dass die äußere Schichtdicke eines mittleren Abschnitts, der die genannte Spule enthält, kleiner als ein Durchmesser der genannten Durchgangsöffnung ausgebildet wird, und ein oberer Abschnitt des genannten Magnetkerns, der an einem oberen Teil der genannten Spule angeordnet wird, und ein unterer Abschnitt des genannten Magnetkerns, der an einem unteren Teil der genannten Spule angeordnet wird, mit einer höheren Dichte als der genannte mittlere Abschnitt ausgebildet werden.
  13. Verfahren nach Anspruch 12, worin der genannte mittlere Abschnitt einen inneren mittleren Abschnitt umfasst, der in der genannten Durchgangsöffnung angeordnet wird, und einen äußeren mittleren Abschnitt umfasst, der an einer äußeren Peripherie der genannten Spule angeordnet wird, und eine Dichte des genannten äußeren mittleren Abschnitts höher als eine Dichte des genannten inneren mittleren Abschnitts ist.
  14. Verfahren nach Anspruch 12, worin die Dichten des genannten oberen Abschnitts und des genannten unteren Abschnitts in einem Bereich von 5,0 bis 6,0 g/cm3 liegen, und die Dichte des genannten mittleren Abschnitts von 85% bis 98% der Dichten des genannten oberen Abschnitts und des genannten unteren Abschnitts ist.
  15. Verfahren nach Anspruch 12, worin der genannte Verkapselungsvorgang weiterhin die Schritte umfasst:
    Ausbilden des komprimierten Pulvers mit Bindemittel, welches härtbares Kunstharz und magnetisches Pulver umfasst; und
    Ausbilden eines verkapselnden Magnetkerns durch Umformen des genanntes komprimiertes Pulver unter Druck, um die genannte Spule zu bedecken.
  16. Verfahren nach Anspruch 15, worin das genannte komprimierte Pulver durch Mischen und Formen ohne Heizen ausgebildet wird, damit das genannte härtbare Kunstharz nicht ausgehärtet wird, und unter Wärme und Druck umgeformt wird, damit das genannte härtbare Kunstharz aushärtet.
  17. Verfahren nach Anspruch 15, worin das genannte Ausbilden des komprimierten Pulvers das Ausbilden eines schwachen Abschnitts und eines starken Abschnitts umfasst, wobei der genannte schwache Abschnitt nicht in der Lage ist, eine Form des genannten komprimierten Pulvers während des genannten Umformens zu bewahren, und der genannte starke Abschnitt in der Lage ist, eine Form des genannten komprimierten Pulvers während des genannten Umformens zu bewahren.
  18. Verfahren nach Anspruch 15, worin das genannte härtbare Kunstharz Silikon-Kunstharz umfasst, welches einen festen Kunstharzbestandteil und einen elastischen Kunstharzbestandteil umfasst.
  19. Verfahren nach Anspruch 17, worin der genannte Ausbildungsvorgang des verkapselnden Magnetkerns in einer solcher Weise durchgeführt wird, dass eine Seite der Spule durch den starken Abschnitt des genannten komprimierten Pulvers getragen wird, während die andere Seite der genannten Spule mit dem genannten schwachen Abschnitt bedeckt wird.
  20. Verfahren nach Anspruch 17, worin der Querschnitt des genannten komprimierten Pulvers eine E-Form mit einem Rückabschnitt, einem Zentralabschnitt und einem Außenabschnitt hat, worin der genannte Rückabschnitt der genannte starke Abschnitt ist, während der genannte Zentralabschnitt und der genannte Außenabschnitt der genannte schwache Abschnitt sind.
  21. Verfahren nach Anspruch 15, worin ein Spitzende des Zentralabschnitts oder des Außenabschnitts des genannten komprimierten Pulvers kleine Spitzen und Senken aufweist.
  22. Verfahren nach Anspruch 15, worin mindestens eine teilende Nut an dem Rückabschnitt des genannten komprimierten Pulvers vorgesehen ist.
EP02700796A 2001-02-27 2002-02-26 Spulenbauteil und verfahren zu seiner herstellung Expired - Lifetime EP1356479B1 (de)

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JP2001051803 2001-02-27
JP2001051803A JP3612028B2 (ja) 2001-02-27 2001-02-27 コイル部品の製造方法
JP2002012515 2002-01-22
JP2002012515A JP3654251B2 (ja) 2002-01-22 2002-01-22 コイル部品
JP2002015051 2002-01-24
JP2002015051A JP3654254B2 (ja) 2002-01-24 2002-01-24 コイル部品の製造方法
PCT/JP2002/001736 WO2002069360A2 (en) 2001-02-27 2002-02-26 Coil component and method of manufacturing the same

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WO2002069360A3 (en) 2002-11-28
DE60208523D1 (de) 2006-03-30
EP1356479A2 (de) 2003-10-29
CN1215494C (zh) 2005-08-17
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MY128606A (en) 2007-02-28
US7015783B2 (en) 2006-03-21

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